Method and apparatus for producing a zoned and/or layered substrate

ABSTRACT

Methods and apparatuses for producing a zoned and/or layered substrate are described. A method can include providing a first supply of fibers, providing a second supply of fibers, and providing a headbox. The headbox can include a machine direction, a cross-direction, and a first cross-directional divider that separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner. The method can further include transferring the first supply of fibers and the second supply of fibers to the headbox. The method can also include transferring the first supply of fibers and the second supply of fibers through the headbox to provide the substrate.

TECHNICAL FIELD

The present disclosure relates to methods and apparatuses that canproduce a zoned and/or layered substrate and such substrates. Morespecifically, the present disclosure relates to foam-forming methods andheadboxes that can produce a zoned and/or layered substrate and suchsubstrates.

BACKGROUND OF THE DISCLOSURE

Current commercial personal care products, such as diapers, diaperpants, training pants, and adult incontinence products, typicallyinclude different components to provide an absorbent structure that areeach typically prepared from different processing lines using differentraw materials. Each component, such as the acquisition material (orsurge), absorbent core, and core wrap (or distribution layer) performswell for its designed purposes. However, the compilation of eachcomponent on a commercial manufacturing line requires that theseseparate materials be bonded to one another, such as through the use ofadhesives. The bonding interface can inhibit performance properties ofthe overall structure in comparison to its designed function andperformance. For example, an adhesive interface between components in anabsorbent composite can resist body fluid penetrating from one componentto the other, which can provide a negative impact on fluid intake anddistribution properties of an absorbent product. Not only can such anadhesive interface reduce fluid handling properties of specificstructures within an absorbent composite, but it can also it negativelyaffect dry product properties, such as softness, flexibility, comfortand fit, etc. Similar issues can exist for layered or zoned products,for example, such as, tissues, wipes, and/or wipers. For example,adhesive bonding between adjacent plies in a tissue product can reducesoftness of the tissue product. Thermal bonding and/or pressure bondingare two other techniques that can be used to combine two separatematerials at discrete points. While such methods may not reduce softnessas much adhesive bonding of separate components, such bonding techniquesmay still provide some negative impact on fluid handling properties atsuch bonded locations.

In addition, current manufacturing practices of creating separatecomponents for an absorbent composite often do not provide theflexibility to provide zoned structural components that can provideenhanced performance within an absorbent structure and higher rawmaterial efficiency or do not provide adequate control over the gradientbetween adjacent zones of a zoned substrate.

Thus, there exists a need to develop a method and apparatus for creatinga zoned and/or layered substrate. There is also a need to develop amethod and apparatus for creating a zoned substrate that can provideenhanced control of the gradient between adjacent zones of a zonedsubstrate. There is also a need to develop multi-layered structureswithout the use of adhesive materials between the layers and that cancontrol the gradient between adjacent layers. There is also a need todevelop multi-layered structures that include zoned substrates withoutthe use of adhesive materials between the layers.

SUMMARY OF THE DISCLOSURE

In one embodiment, a method for manufacturing a substrate is provided.The method can include providing a first supply of fibers, providing asecond supply of fibers, and providing a headbox. The headbox caninclude a machine direction, a cross-direction, and a firstcross-directional divider. The first cross-directional divider canseparate a first zone of the headbox from a second zone of the headboxin a cross-directional manner. The method can further includetransferring the first supply of fibers and the second supply of fibersto the headbox. The method can also include transferring the firstsupply of fibers and the second supply of fibers through the headbox toprovide the substrate.

In another embodiment, a divider for a headbox is provided. The headboxcan include a cross direction and a machine direction. The divider caninclude a first surface and a second surface. The second surface can beopposite from the first surface. The divider can include a width definedin the cross direction. The divider can include a length defined in themachine direction. The divider can include a first cross-directionaldivider extending away from the first surface. The firstcross-directional divider can include a cross-directional thickness anda machine-directional length.

In yet another embodiment, a headbox for manufacturing a substrate isprovided. The headbox can include a machine direction and a crossdirection. The headbox can further include an inlet, an outlet, aninternal chamber, and a divider. The divider can at least partially bewithin the internal chamber. The divider can include a first surface anda second surface. The second surface can be opposite from the firstsurface. The divider can include a width defined in the cross direction.The divider can include a length defined in the machine direction. Thedivider can further include a first cross-directional divider extendingaway from the first surface of the divider. The first cross-directionaldivider can include a cross-directional thickness and amachine-directional length. The divider can separate a firstz-directional layer of the headbox from a second z-directional layer ofthe headbox. The first cross-directional divider separates a first zoneof the headbox from a second zone of the headbox in a cross-directionalmanner. The first zone and the second zone can be in the firstz-directional layer.

In still another embodiment, a method for manufacturing a substrateincluding a first layer and a second layer is provided. The method caninclude providing a first supply of fibers. The method can includeproviding a supply of particulates. The method can also includeproviding a headbox. The headbox can include a machine direction, across-direction, and a z-direction. The z-direction can be perpendicularto a plane defined by the machine direction and the cross-direction. Theheadbox can also include a divider. The divider can include a firstsurface, a second surface opposite the first surface, a width extendingin the cross-direction, and a length extending in the machine direction.The divider can separate a first z-directional layer of the headbox froma second z-directional layer of the headbox. The method can furtherinclude setting a z-directional position of the divider in the headboxto provide a target relative thickness setting of the secondz-directional layer of the headbox. The method can also includetransferring the first supply of fibers and the supply of particulatesto the headbox such that the first supply of fibers enter the firstz-directional layer of the headbox and the supply of particulates enterthe second z-directional layer of the headbox. The method canadditionally include controlling the first supply of fibers and thesupply of particulates through the headbox to a forming surface suchthat a relative thickness of the second layer of the substrate isprovided with less than 20% variation of the target relative thicknesssetting of the second z-directional layer of the headbox.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure thereof, directed to one of ordinaryskill in the art, is set forth more particularly in the remainder of thespecification, which makes reference to the appended figures in which:

FIG. 1 is a side plan view of an exemplary headbox including a dividerthat can provide a zoned substrate of the present disclosure.

FIG. 2 is a top, perspective view of a divider, such as utilized in FIG.1 .

FIG. 3 is a cross-section view taken along line 3-3 from FIG. 2 .

FIG. 4 is a top plan view of an exemplary inlet section to the headboxof FIG. 1

FIG. 5A is a cross-section view of an exemplary zoned substrate of thepresent disclosure that can be provided by the headbox and divider asillustrated in FIG. 4 .

FIG. 5B is a cross-section view of an alternative exemplary zonedsubstrate of the present disclosure that can be provided by the headboxand divider as illustrated in FIG. 4 .

FIG. 5C is a cross-section view of yet another alternative exemplaryzoned substrate of the present disclosure that can be provided by theheadbox and divider as illustrated in FIG. 4 .

FIG. 6 is a cross-section view of an alternative divider that can beutilized in a headbox, such as illustrated in FIG. 1 .

FIG. 7 is a cross-section view of another zoned substrate of the presentdisclosure that can be provided by the headbox and divider asillustrated in FIGS. 1 and 6 .

FIG. 8A is a photograph of an exemplary zoned substrate produced by aheadbox and divider as illustrated in FIG. 4 .

FIG. 8B is a photograph of an exemplary zoned substrate produced by adivider with no cross-directional dividers.

FIG. 8C is a photograph of a zoned substrate that was produced by aheadbox with no divider.

FIG. 9A is a microCT image of a cross-section of the substrate of FIG.8A.

FIG. 9B is a microCT image of a cross-section of the substrate of FIG.8B.

FIG. 9C is a microCT image of a cross-section of the substrate of FIG.8C.

FIG. 10 is a graph depicting fluid distribution versus product lengthfor exemplary codes.

FIG. 11 is an exemplary analysis used in the Purity Gradient TestMethod.

FIG. 12 is an exemplary analysis used in the Layer Relative ThicknessTest Method.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure is directed to methods and apparatuses that canproduce a zoned and/or layered substrate and such substrates. While thepresent disclosure provides examples of zoned and/or layered substratesmanufactured through foam-forming, it is contemplated that the methodsand apparatuses described herein may be utilized to benefit wet-laidand/or air-laid manufacturing processes.

Each example is provided by way of explanation and is not meant as alimitation. For example, features illustrated or described as part ofone embodiment or figure can be used on another embodiment or figure toyield yet another embodiment. It is intended that the present disclosureinclude such modifications and variations.

When introducing elements of the present disclosure or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. As used herein, the terminology of “first,” “second,” “third”,etc. does not designate a specified order, but is used as a means todifferentiate between different occurrences when referring to variousfeatures in the present disclosure. Many modifications and variations ofthe present disclosure can be made without departing from the spirit andscope thereof. Therefore, the exemplary embodiments described hereinshould not be used to limit the scope of the invention.

Definitions

As used herein, the term “foam formed product” means a product formedfrom a suspension including a mixture of a solid, a liquid, anddispersed gas bubbles.

As used herein, the term “foam forming process” means a process formanufacturing a product involving a suspension including a mixture of asolid, a liquid, and dispersed gas bubbles.

As used herein, the term “foaming fluid” means any one or more knownfluids compatible with the other components in the foam forming process.Suitable foaming fluids include, but are not limited to, water.

As used herein, the term “foam half life” means the time elapsed untilthe half of the initial frothed foam mass reverts to liquid water.

As used herein, the term “layer” refers to a structure that provides anarea of a substrate in a z-direction of the substrate that is comprisedof similar components and structure.

As used herein, the term “nonwoven web” means a web having a structureof individual fibers or threads which are interlaid, but not in anidentifiable manner as in a knitted web.

As used herein, unless expressly indicated otherwise, when used inrelation to material compositions the terms “percent”, “%”, “weightpercent”, or “percent by weight” each refer to the quantity by weight ofa component as a percentage of the total except as whether expresslynoted otherwise.

The term “personal care absorbent article” refers herein to an articleintended and/or adapted to be placed against or in proximity to the body(i.e., contiguous with the body) of the wearer to absorb and containvarious liquid, solid, and semi-solid exudates discharged from the body.Examples include, but are not limited to, diapers, diaper pants,training pants, youth pants, swim pants, feminine hygiene products,including, but not limited to, menstrual pads or pants, incontinenceproducts, medical garments, surgical pads and bandages, and so forth.

The term “ply” refers to a discrete layer within a multi-layered productwherein individual plies may be arranged in juxtaposition to each other.

The term “plied” or “bonded” or “coupled” refers herein to the joining,adhering, connecting, attaching, or the like, of two elements. Twoelements will be considered plied, bonded or coupled together when theyare joined, adhered, connected, attached, or the like, directly to oneanother or indirectly to one another, such as when each is directlybonded to intermediate elements. The plying, bonding or coupling of oneelement to another can occur via continuous or intermittent bonds.

The term “superabsorbent material” as used herein refers towater-swellable, water-insoluble organic or inorganic materialsincluding superabsorbent polymers and superabsorbent polymercompositions capable, under the most favorable conditions, of absorbingat least about 10 times their weight, or at least about 15 times theirweight, or at least about 25 times their weight in an aqueous solutioncontaining 0.9 weight percent sodium chloride.

The term “zone” as used herein with respect to a substrate refers to aparticular area of a substrate in the cross-direction of the substratethat is comprised of similar components and structure.

Method and Apparatus

In one embodiment, the present disclosure relates to a foam formingprocess and associated method that can be employed to manufacturing azoned substrate 10, 110, 210, 310. FIG. 1 provides an exemplaryapparatus 12 that can be used as part of a foam forming process tomanufacture a foam formed product. The apparatus 12 of FIG. 1 can formpart of a foam forming process that can include a pulper that can mixfibers, a fluid, and a surfactant, as will be discussed in greaterdetail below. The pulper can mix (e.g., agitates) the surfactant and thefluid (e.g., water) with air to create a foam. The pulper also mixes thefoam with the fibers to create a foam suspension of fibers in which thefoam holds and separates the fibers to facilitate a distribution of thefibers within the foam (e.g., as an artifact of the mixing process inthe pulper). Uniform fiber distribution can promote desirable nonwovenmaterial characteristics including, for example, strength and the visualappearance of quality.

Foaming Fluid

The foam forming processes as described herein can include a foamingfluid. In some embodiments, the foaming fluid can comprise between about85% to about 99.99% of the foam (by weight). In some embodiments, thefoaming fluid used to make the foam can comprise at least about 85% ofthe foam (by weight). In certain embodiments, the foaming fluid cancomprise between about 90% and about 99.9% % of the foam (by weight). Incertain other embodiments, the foaming fluid can comprise between about93% and 99.5% of the foam or even between about 95% and about 99.0% ofthe foam (by weight). In preferred embodiments, the foaming fluid can bewater, however, it is contemplated that other processes may utilizeother foaming fluids.

Foaming Surfactant

The foam forming processes as described herein can utilize one of moresurfactants. The fibers and surfactant, together with the foaming liquidand any additional components, can form a stable dispersion capable ofsubstantially retaining a high degree of porosity for longer than thedrying process. In this regard, the surfactant is selected so as toprovide a foam having a foam half life of at least 2 minutes, moredesirably at least 5 minutes, and most desirably at least 10 minutes. Afoam half life can be a function of surfactant types, surfactantconcentrations, foam compositions/solid level and mixing power/aircontent in a foam. The foaming surfactant used in the foam can beselected from one or more known in the art that are capable of providingthe desired degree of foam stability. In this regard, the foamingsurfactant can be selected from anionic, cationic, nonionic andamphoteric surfactants provided they, alone or in combination with othercomponents, provide the necessary foam stability, or foam half life. Aswill be appreciated, more than one surfactant can be used, includingdifferent types of surfactants, as long as they are compatible, and morethan one surfactant of the same type. For example, a combination of acationic surfactant and a nonionic surfactant or a combination of ananionic surfactant and a nonionic surfactant may be used in someembodiments due to their compatibilities. However, in some embodiments,a combination of a cationic surfactant and an anionic surfactant may notbe satisfactory to combine due to incompatibilities between thesurfactants.

Anionic surfactants believed suitable for use with the presentdisclosure include, without limitation, anionic sulfate surfactants,alkyl ether sulfonates, alkylaryl sulfonates, or mixtures orcombinations thereof. Examples of alkylaryl sulfonates include, withoutlimitation, alkyl benzene sulfonic acids and their salts, dialkylbenzenedisulfonic acids and their salts, dialkylbenzene sulfonic acids andtheir salts, alkylphenol sulfonic acids/condensed alkylphenol sulfonicacids and their salts, or mixture or combinations thereof. Examples ofadditional anionic surfactants believed suitable for use in the presentdisclosure include alkali metal sulforicinates, sulfonated glycerylesters of fatty acids such as sulfonated monoglycerides of coconut oilacids, salts of sulfonated monovalent alcohol esters such as sodiumoleylisethianate, metal soaps of fatty acids, amides of amino sulfonicacids such as the sodium salt of oleyl methyl tauride, sulfonatedproducts of fatty acids nitriles such as palmitonitrile sulfonate,alkali metal alkyl sulfates such as sodium lauryl sulfate, ammoniumlauryl sulfate or triethanolamine lauryl sulfate, ether sulfates havingalkyl groups of 8 or more carbon atoms such as sodium lauryl ethersulfate, ammonium lauryl ether sulfate, sodium alkyl aryl ethersulfates, and ammonium alkyl aryl ether sulfates, sulphuric esters ofpolyoxyethylene alkyl ether, sodium salts, potassium salts, and aminesalts of alkylnapthylsulfonic acid. Certain phosphate surfactantsincluding phosphate esters such as sodium lauryl phosphate esters orthose available from the Dow Chemical Company under the tradename TRITONare also believed suitable for use herewith. A particularly desiredanionic surfactant is sodium dodecyl sulfate (SDS).

Cationic surfactants are also believed suitable for use with the presentdisclosure for manufacturing some embodiments of substrates. In someembodiments, such as those including superabsorbent material, cationicsurfactants may be less preferable to use due to potential interactionbetween the cationic surfactant(s) and the superabsorbent material,which may be anionic. Foaming cationic surfactants include, withoutlimitation, monocarbyl ammonium salts, dicarbyl ammonium salts,tricarbyl ammonium salts, monocarbyl phosphonium salts, dicarbylphosphonium salts, tricarbyl phosphonium salts, carbylcarboxy salts,quaternary ammonium salts, imidazolines, ethoxylated amines, quaternaryphospholipids and so forth. Examples of additional cationic surfactantsinclude various fatty acid amines and amides and their derivatives, andthe salts of the fatty acid amines and amides. Examples of aliphaticfatty acid amines include dodecylamine acetate, octadecylamine acetate,and acetates of the amines of tallow fatty acids, homologues of aromaticamines having fatty acids such as dodecylanalin, fatty amides derivedfrom aliphatic diamines such as undecylimidazoline, fatty amides derivedfrom aliphatic diamines such as undecylimidazoline, fatty amides derivedfrom disubstituted amines such as oleylaminodiethylamine, derivatives ofethylene diamine, quaternary ammonium compounds and their salts whichare exemplified by tallow trimethyl ammonium chloride,dioctadecyldimethyl ammonium chloride, didodecyldimethyl ammoniumchloride, dihexadecyl ammonium chloride, alkyltrimethylammoniumhydroxides, dioctadecyldimethylammonium hydroxide, tallowtrimethylammonium hydroxide, trimethylammonium hydroxide,methylpolyoxyethylene cocoammonium chloride, and dipalmitylhydroxyethylammonium methosulfate, amide derivatives of amino alcoholssuch as beta-hydroxylethylstearylamide, and amine salts of long chainfatty acids. Further examples of cationic surfactants believed suitablefor use with the present disclosure include benzalkonium chloride,benzethonium chloride, cetrimonium bromide, distearyldimethylammoniumchloride, tetramethylammonium hydroxide, and so forth.

Nonionic surfactants believed suitable for use in the present disclosureinclude, without limitation, condensates of ethylene oxide with a longchain fatty alcohol or fatty acid, condensates of ethylene oxide with anamine or an amide, condensation products of ethylene and propyleneoxides, fatty acid alkylol amide and fatty amine oxides. Variousadditional examples of non-ionic surfactants include stearyl alcohol,sorbitan monostearate, octyl glucoside, octaethylene glycol monododecylether, lauryl glucoside, cetyl alcohol, cocamide MEA, monolaurin,polyoxyalkylene alkyl ethers such as polyethylene glycol long chain(12-14C) alkyl ether, polyoxyalkylene sorbitan ethers, polyoxyalkylenealkoxylate esters, polyoxyalkylene alkylphenol ethers, ethylene glycolpropylene glycol copolymers, polyvinyl alcohol, alkylpolysaccharides,polyethylene glycol sorbitan monooleate, octylphenol ethylene oxide, andso forth.

The foaming surfactant can be used in varying amounts as necessary toachieve the desired foam stability and air-content in the foam. Incertain embodiments, the foaming surfactant can comprise between about0.005% and about 5% of the foam (by weight). In certain embodiments thefoaming surfactant can comprise between about 0.05% and about 3% of thefoam or even between about 0.05% and about 2% of the foam (by weight).

Fibers

The foam suspension of fibers can provide one or more supply of fibers.In some embodiments, the fibers utilized herein can include naturalfibers and/or synthetic fibers. In some embodiments, a fiber supply caninclude only natural fibers or only synthetic fibers. In otherembodiments, a fiber supply can include a mixture of natural fibers andsynthetic fibers. Some fibers being utilized herein can be absorbent,whereas other fibers utilized herein can be non-absorbent. Non-absorbentfibers can provide features for the substrates that are formed from themethods and apparatuses described herein, such as improved intake ordistribution of fluids.

A wide variety of cellulosic fibers are believed suitable for useherein. In some embodiments, the fibers utilized can be conventionalpapermaking fibers such as wood pulp fibers formed by a variety ofpulping processes, such as kraft pulp, sulfite pulp, bleachedchemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP),pressure/pressure thermomechanical pulp (PIMP), thermomechanical pulp(TMP), thermomechanical chemical pulp (TMCP), and so forth. By way ofexample only, fibers and methods of making wood pulp fibers aredisclosed in U.S. Pat. No. 4,793,898 to Laamanen et al.; U.S. Pat. No.4,594,130 to Chang et al.; U.S. Pat. No. 3,585,104 to Kleinhart; U.S.Pat. No. 5,595,628 to Gordon et al.; U.S. Pat. No. 5,522,967 to Shet;and so forth. Further, the fibers may be any high-average fiber lengthwood pulp, low-average fiber length wood pulp, or mixtures of the same.Examples of suitable high-average length pulp fibers include softwoodfibers, such as, but not limited to, northern softwood, southernsoftwood, redwood, red cedar, hemlock, pine (e.g., southern pines),spruce (e.g., black spruce), and the like. Examples of suitablelow-average length pulp fibers include hardwood fibers, such as, but notlimited to, eucalyptus, maple, birch, aspen, and the like.

Moreover, if desired, secondary fibers obtained from recycled materialsmay be used, such as fiber pulp from sources such as, for example,newsprint, reclaimed paperboard, and office waste. In a particularlypreferred embodiment refined fibers are utilized in the tissue web suchthat the total amount of virgin and/or high average fiber length woodfibers, such as softwood fibers, may be reduced.

Regardless of the origin of the wood pulp fiber, the wood pulp fiberspreferably have an average fiber length greater than about 0.2 mm andless than about 3 mm, such as from about 0.35 mm and about 2.5 mm, orbetween about 0.5 mm to about 2 mm or even between about 0.7 mm andabout 1.5 mm.

In addition, other cellulosic fibers that can be used in the presentdisclosure includes nonwoody fibers. As used herein, the term “non-woodfiber” generally refers to cellulosic fibers derived from non-woodymonocotyledonous or dicotyledonous plant stems. Non-limiting examples ofdicotyledonous plants that may be used to yield non-wood fiber includekenaf, jute, flax, ramie and hemp. Non-limiting examples ofmonocotyledonous plants that may be used to yield non-wood fiber includecereal straws (wheat, rye, barley, oat, etc.), stalks (corn, cotton,sorghum, Hesperaloe funifera, etc.), canes (bamboo, sisal, bagasse,etc.) and grasses (miscanthus. esparto, lemon, sabai, switchgrass, etc).In still other certain instances non-wood fiber may be derived fromaquatic plants such as water hyacinth, microalgae such as Spirulina, andmacroalgae seaweeds such as red or brown algae.

Still further, other cellulosic fibers for making substrates herein caninclude synthetic cellulose fiber types formed by spinning, includingrayon in all its varieties, and other fibers derived from viscose orchemically-modified cellulose such as, for example, those availableunder the trade names LYOCELL and TENCEL. Some chemically-modifiedcellulose fibers that can be employed in substrates described herein caninclude chemically crosslinked pulp fibers, such as CMC535 fibersproduced by International Paper.

In some embodiments, the non-woody and synthetic cellulosic fibers canhave fiber length greater than about 0.2 mm including, for example,having an average fiber size between about 0.5 mm and about 50 mm orbetween about 0.75 and about 30 mm or even between about 1 mm and about25 mm. Generally speaking, when fibers of relatively larger averagelength are being used, it may often be advantageous to modify the amountand type of foaming surfactant. For example, in some embodiments, iffibers of relatively larger average length are being used, it may bebeneficial to utilize relatively higher amounts of foaming surfactant inorder to help achieve a foam with the required foam half life.

Additional fibers that may be utilized in the present disclosure includefibers that are resistant to the forming fluid, namely those that arenon-absorbent and whose bending stiffness is substantially unimpacted bythe presence of forming fluid. As noted above, typically the formingfluid will comprise water. By way of non-limiting example,water-resistant fibers include fibers such as polymeric fiberscomprising polyolefin, polyester (PET), polyamide, polylactic acid, orother fiber forming polymers. Polyolefin fibers, such as polyethylene(PE) and polypropylene (PP), are particularly well suited for use in thepresent disclosure. In some embodiments, non-absorbent fibers can berecycled fibers, compostable fibers, and/or marine degradable fibers. Inaddition, highly cross-linked cellulosic fibers having no-significantabsorbent properties can also be used herein. In this regard, due to itsvery low levels of absorbency to water, water resistant fibers do notexperience a significant change in bending stiffness upon contacting anaqueous fluid and therefore are capable of maintain an open compositestructure upon wetting. The fiber composition and diameter of a fibercan contribute to enhanced bending stiffness. For example, a PET fiberhas a higher bending stiffness than a polyolefin fiber whether in dry orwet states due to composition. The higher the fiber diameter, the higherthe bending stiffness a fiber exhibits. Water resistant fibers desirablyhave a water retention value (WRV) less than about 1 and still moredesirably between about 0 and about 0.5. In certain aspects, it isdesirable that the fibers, or at least a portion thereof, includenon-absorbent fibers.

The synthetic and/or water resistant fibers can have fiber lengthgreater than about 0.2 mm including, for example, having an averagefiber size between about 0.5 mm and about 50 mm or between about 0.75and about 30 mm or even between about 1 mm and about 25 mm.

In some embodiments, the synthetic and/or water resistant fibers canhave a crimped structure to enhance bulk generation capability of thefoam formed fibrous substrate. For example, a PET crimped staple fibermay be able to generate a higher caliper (or result in a low sheetdensity) in comparison to a PET straight staple fiber with the samefiber diameter and fiber length.

In some embodiments, the total content of fibers, can comprise betweenabout 0.01% to about 10% of the foam (by weight), and in someembodiments between about 0.1% to about 5% of the foam (by weight).

Binder

In some embodiments, a foam as provided herein can include bindermaterials. Binder materials that may be used in the present disclosurecan include, but are not limited to, thermoplastic binder fibers, suchas PET/PE bicomponent binder fiber, and water-compatible adhesives suchas, for example, latexes. In some embodiments, binder materials as usedherein can be in powder form, for example, such as thermoplastic PEpowder. Importantly, the binder can comprise one that is water insolubleon the dried substrate. In certain embodiments, latexes used in thepresent disclosure can be cationic or anionic to facilitate applicationto and adherence to cellulosic fibers that can be used herein. Forinstance, latexes believed suitable for use include, but are not limitedto, anionic styrene-butadiene copolymers, polyvinyl acetatehomopolymers, vinyl-acetate ethylene copolymers, vinyl-acetate acryliccopolymers, ethylene-vinyl chloride copolymers, ethylene-vinylchloride-vinyl acetate terpolymers, acrylic polyvinyl chloride polymers,acrylic polymers, nitrile polymers, as well as other suitable anioniclatex polymers known in the art. Examples of such latexes are describedin U.S. Pat. No. 4,785,030 to Hager, U.S. Pat. No. 6,462,159 to Hamada,U.S. Pat. No. 6,752,905 to Chuang et al. and so forth. Examples ofsuitable thermoplastic binder fibers include, but are not limited to,monocomponent and multi-component fibers having at least one relativelylow melting thermoplastic polymer such as polyethylene. In certainembodiments, polyethylene/polypropylene sheath/core staple fibers can beused. Binder fibers may have lengths in line with those described hereinabove in relation to the synthetic cellulosic fibers.

Exemplary commercially available binder fibers include T 255 binderfiber with a 6 or 12 mm fiber length and a 2.2 dtex fiber diameter fromTrevia or WL Adhesion C binder fiber with a 4 mm fiber length and a 1.7dtex fiber diameter from FiberVisions.

Binders in liquid form, such as latex emulsions, can comprise betweenabout 0% and about 10% of the foam (by weight). In certain embodimentsthe non-fibrous binder can comprise between about 0.1% and 10% of thefoam (by weight) or even between about 0.2% and about 5% or even betweenabout 0.5% and about 2% of the foam (by weight). Binder fibers, whenused, may be added proportionally to the other components to achieve thedesired fiber ratios and structure while maintaining the total solidscontent of the foam below the amounts stated above. As an example, insome embodiments, binder fibers can comprise between about 0% and about50% of the total fiber weight, and more preferably, between about 5% toabout 40% of the total fiber weight in some embodiments.

Foam Stabilizers

The foam may optionally also include one or more foam stabilizers knownin the art and that are compatible with the components of the foam andfurther do not interfere with the hydrogen bonding as between thecellulosic fibers. Foam stabilizing agents believed suitable for use inthe present disclosure, without limitation, one or more zwitterioniccompounds, amine oxides, alkylated polyalkylene oxides, or mixture orcombinations thereof. Specific examples of foam stabilizers includes,without limitation, cocoamine oxide, isononyldimethylamine oxide,n-dodecyldimethylamine oxide, and so forth.

In some embodiments, if utilized, the foam stabilizer can comprisebetween about 0.01% and about 2% of the foam (by weight). In certainembodiments, the foam stabilizer can comprise between about 0.05% and 1%of the foam or even between about 0.1 and about 0.5% of the foam (byweight).

Additional Additives

In the methods as described herein, the foam forming process can includeadding one or more additional additives. For example, one additionaladditive that can be added during the formation of the substrates 10 asdescribed herein can be a superabsorbent materials (SAM). SAM iscommonly provided in a particulate form and, in certain aspects, cancomprise polymers of unsaturated carboxylic acids or derivativesthereof. These polymers are often rendered water insoluble, but waterswellable, by crosslinking the polymer with a di- or polyfunctionalinternal crosslinking agent. These internally cross-linked polymers areat least partially neutralized and commonly contain pendant anioniccarboxyl groups on the polymer backbone that enable the polymer toabsorb aqueous fluids, such as body fluids. Typically, the SAM particlesare subjected to a post-treatment to crosslink the pendant anioniccarboxyl groups on the surface of the particle. SAMs are manufactured byknown polymerization techniques, desirably by polymerization in aqueoussolution by gel polymerization. The products of this polymerizationprocess are aqueous polymer gels, i.e., SAM hydrogels that are reducedin size to small particles by mechanical forces, then dried using dryingprocedures and apparatus known in the art. The drying process isfollowed by pulverization of the resulting SAM particles to the desiredparticle size. Examples of superabsorbent materials include, but are notlimited to, those described in U.S. Pat. No. 7,396,584 Azad et al., U.S.Pat. No. 7,935,860 Dodge et al., US2005/5245393 to Azad et al.,US2014/09606 to Bergam et al., WO2008/027488 to Chang et al. and soforth. In addition, in order to aid processing, the SAM may be treatedin order to render the material temporarily non-absorbing during theformation of the foam and formation of the highly-expanded foam. Forexample, in one aspect, the SAM may be treated with a water-solubleprotective coating having a rate of dissolution selected such that theSAM is not substantially exposed to the aqueous carrier until thehighly-expanded foam has been formed and drying operations initiated.Alternatively, in order to prevent or limit premature expansion duringprocessing, the SAM may be introduced into the process at lowtemperatures.

In some embodiments incorporating SAM, the SAM can comprise betweenabout 0% and about 40% of the foam (by weight). In certain embodiments,SAM can comprise between about 1% and about 30% of the foam (by weight)or even between about 10% and about 30% of the foam (by weight).

Other additional agents can include one or more wet strength additivesthat can be added to the foam in order to help improve the relativestrength of the ultra-low density composite cellulosic material. Suchstrength additives suitable for use with paper making fibers and themanufacture of paper tissue are known in the art. Temporary wet strengthadditives may be cationic, nonionic or anionic. Examples of suchtemporary wet strength additives include PAREZ™ 631 NC and PAREZ® 725temporary wet strength resins that are cationic glyoxylatedpolyacrylamides available from Cytec Industries, located at WestPaterson, N.J. These and similar resins are described in U.S. Pat. No.3,556,932 to Coscia et al. and U.S. Pat. No. 3,556,933 to Williams etal. Additional examples of temporary wet strength additives includedialdehyde starches and other aldehyde containing polymers such as thosedescribed in U.S. Pat. No. 6,224,714 to Schroeder et al.; U.S. Pat. No.6,274,667 to Shannon et al.; U.S. Pat. No. 6,287,418 to Schroeder etal.; and U.S. Pat. No. 6,365,667to Shannon et al., and so forth.

Permanent wet strength agents comprising cationic oligomeric orpolymeric resins may also be used in the present disclosure.Polyamide-polyamine-epichlorohydrin type resins such as KYMENE 557H soldby Solenis are the most widely used permanent wet-strength agents andare suitable for use in the present disclosure. Such materials have beendescribed in the following U.S. Pat. No. 3,700,623 to Keim; U.S. Pat.No. 3,772,076 to Keim; U.S. Pat. No. 3,855,158 to Petrovich et al.; U.S.Pat. No. 3,899,388to Petrovich et al.; U.S. Pat. No. 4,129,528 toPetrovich et al.; U.S. Pat. No. 4,147,586 to Petrovich et al.; U.S. Pat.No. 4,222,921 to van Eenam and so forth. Other cationic resins includepolyethylenimine resins and aminoplast resins obtained by reaction offormaldehyde with melamine or urea. Permanent and temporary wet strengthresins may be used together in the manufacture of composite cellulosicproducts of the present disclosure. Further, dry strength resins mayalso optionally be applied to the composite cellulosic webs of thepresent disclosure. Such materials may include, but are not limited to,modified starches and other polysaccharides such as cationic,amphoteric, and anionic starches and guar and locust bean gums, modifiedpolyacrylamides, carboxymethylcellulose, sugars, polyvinyl alcohol,chitosan, and the like.

If used, such wet and dry strength additives can comprise between about0.01 and about 5% of the dry weight of cellulose fibers. In certainembodiments, the strength additives can comprise between about 0.05% andabout 2% of the dry weight of cellulose fibers or even between about0.1% and about 1% of the dry weight of cellulose fibers.

Still other additional components may be added to the foam so long asthey do not significantly interfere with the formation of thehighly-expanded stable foam, the hydrogen bonding as between thecellulosic fibers or other desired properties of the web. As examples,additional additives may include one or more pigments, opacifyingagents, anti-microbial agents, pH modifiers, skin benefit agents, odorabsorbing agents, fragrances, thermally expandable microspheres,pulverized foam particles and so forth as desired to impart or improveone or more physical or aesthetic attributes. In certain embodiments thecomposite cellulosic webs may include skin benefit agents such as, forexample, antioxidants, astringents, conditioners, emollients,deodorants, external analgesics, film formers, humectants, hydrotropes,pH modifiers, surface modifiers, skin protectants, and so forth.

When employed, miscellaneous additives desirably comprise less thanabout 2% of the foam (by weight) and still more desirably less thanabout 1% of the foam (by weight) and even less than about 0.5% of thefoam (by weight).

In some embodiments, the solids content, including the fibers orparticulates contained herein, desirably comprise no more than about 40%of the foam. In certain embodiments the cellulosic fibers can comprisebetween about 0.1% and about 5% of the foam or between about 0.2 andabout 4% of the foam or even between about 0.5% and about 2% of thefoam.

Formation of Foam

The foaming fluid and any other surfactant(s) or other fibers or agentsis acted upon to form a foam. In some embodiments, the foaming fluid andother components are acted upon so as to form a porous foam having anair content greater than about 50% by volume and desirably an aircontent greater than about 60% by volume. In certain aspects, thehighly-expanded foam is formed having an air content of between about60% and about 95% and in further aspects between about 65% and about85%. In certain embodiments, the foam may be acted upon to introduce airbubbles such that the ratio of expansion (volume of air to othercomponents in the expanded stable foam) is greater than 1:1 and incertain embodiments the ratio of air:other components can be betweenabout 1.1:1 and about 20:1 or between about 1.2:1 and about 15:1 orbetween about 1.5:1 and about 10:1 or even between about 2:1 and about5:1.

The foam can be generated by one or more means known in the art.Examples of suitable methods include, without limitation, aggressivemechanical agitation, injection of compressed air, and so forth. Mixingthe components through the use of a high-shear, high-speed mixer isparticularly well suited for use in the formation of the desiredhighly-porous foams. Various high-shear mixers are known in the art andbelieved suitable for use with the present disclosure. High-shear mixerstypically employ a tank holding the foam precursor and/or one or morepipes through which the foam precursor is directed. The high-shearmixers may use a series of screens and/or rotors to work the precursorand cause aggressive mixing of the components and air. In a particularembodiment, a tank is provided having therein one or more rotors orimpellors and associated stators. The rotors or impellors are rotated athigh speeds in order to cause flow and shear. Air may, for example, beintroduced into the tank at various positions or simply drawn in by theaction of the mixer. While the specific mixer design may influence thespeeds necessary to achieve the desired mixing and shear, in certainembodiments suitable rotor speeds may be greater than about 500 rpm and,for example, be between about 1000 rpm and about 6000 rpm or betweenabout 2000 rpm and about 4000 rpm. In certain embodiments, with respectto rotor based high-shear mixers, the mixer maybe run with the foamuntil the disappearance of the vortex in the foam or a sufficient volumeincrease is achieved.

In addition, it is noted the foaming process can be accomplished in asingle foam generation step or in sequential foam generation steps. Forexample, in one embodiment, all of the components may be mixed togetherto form a slurry from which a foam is formed. Alternatively, one or moreof the individual components may be added to the foaming fluid, aninitial mixture formed (e.g. a dispersion or foam), after which theremaining components may be added to the initially foamed slurry andthen all of the components acted upon to form the final foam. In thisregard, the water and foaming surfactant may be initially mixed andacted upon to form an initial foam prior to the addition of any solids.Fibers may then be added to the water/surfactant foam and then furtheracted upon to form the final foam. As a further alternative, the waterand fibers, such as a high density cellulose pulp sheet, may beaggressively mixed at a higher consistency to form an initial dispersionafter which the foaming surfactant, additional water and othercomponents, such as synthetic fibers, are added to form a second mixturewhich is then mixed and acted upon to form the foam.

The foam density of the foam can vary depending upon the particularapplication and various factors, including the fiber stock used. In someimplementations, for example, the foam density of the foam can begreater than about 100 g/L, such as greater than about 250 g/L, such asgreater than about 300 g/L. The foam density is generally less thanabout 800 g/L, such as less than about 500 g/L, such as less than about400 g/L, such as less than about 350 g/L. In some implementations, forexample, a lower density foam is used having a foam density of generallyless than about 350 g/L, such as less than about 340 g/L, such as lessthan about 330 g/L.

Foam Forming Zoned and/or Layered Substrate

A first supply 14 of fibers can be transported to a headbox 16, such asillustrated in FIG. 1 , via conduit(s) 18. Although one conduit 18 isillustrated in FIG. 1 for transporting the first supply 14 of fibers tothe headbox 16, it is contemplated that more than one conduit 18 cansupply the first supply 14 of fibers to the headbox 16. A second supply15 of fibers can also be transported to the headbox 16. In someembodiments, the second supply 15 of fibers can include different fibersthan the first supply 14 of fibers. In some embodiments, the secondsupply 15 of fibers can include the same fibers as the first supply 14of fibers. In some embodiments, the second supply 15 of fibers can beprovided from a foam slurry that is different from the foam slurryproviding the first supply 14 of fibers in at least one characteristic.The second supply 15 of fibers can be transported to the headbox 16 viaconduit 19. It is contemplated that the second supply 15 of fibers canbe transported to the headbox 16 in more than one conduit 19.

The headbox 16 illustrated in FIG. 1 can be a vertical twin-wire headbox16, as generally known in the art. The headbox 16 as illustrated in FIG.1 can include first and second foraminous elements 20, 22. The first andsecond foraminous elements 20, 22 can help define an interior volume 24of the headbox 16. The headbox 16 can include an inlet 26 and an outlet28. A series of vacuum elements 30 can be disposed adjacent eachforaminous elements 20, 22. The vacuum elements 30 can help to dewaterthe foam that is delivered to the headbox 16 and deposited on theforaminous elements 20, 22.

The headbox 16 can include a machine direction 32, a cross-direction 34,and a z-direction 35 perpendicular to a plane defined by the machinedirection 32 and the cross-direction 34 of the headbox 16. In FIG. 1 ,the machine direction 32 can be viewed in a downward direction, or bedefined as extending from the inlet 26 of the headbox 16 to the outlet28 of the headbox 16. Although the discussion herein is referred to withrespect to a vertical twin-wire headbox 16, it is to be appreciated thatthe methods and apparatuses discussed herein can be utilized with otherheadbox 16 configurations and orientations.

With reference to FIGS. 2-4 , the headbox 16 can include a divider 36.The divider 36 can include at least one cross-directional divider 38.For example, in FIGS. 2-4 , the divider 36 depicted includes twocross-directional dividers 38. One cross-directional divider 38 isspaced apart from the other cross-directional divider 38 in thecross-direction 34 of the headbox 16. In some embodiments, the divider36 can include a first surface 40 and a second surface 42. The secondsurface 42 can be opposite from the first surface 40 of the divider 36.The divider 36 can include a width 44 in the cross-direction 34 and alength 46 in the machine direction 32. In some embodiments, the length46 of the divider 36 can be configured to be at least 50% of the lengthL of the headbox 16 (as labeled in FIG. 1 ), or at least 60% of thelength L of the headbox 16, or at least 65% of the length L of theheadbox 16, or at least 70% of the length of the headbox, or at least75% of the length L of the headbox 16.

The cross-directional divider 38 can extend away from the first surface40. In some embodiments, such as the embodiment depicted in FIGS. 2-4 ,the divider 36 can include two or more cross-directional dividers 38that extend away from the first surface 40 in the same direction.However, it is contemplated that in some embodiments the divider 36could include one or more cross-directional dividers 38 that extend awayfrom the first surface 40 and one or more cross-directional dividers 38that extend away from the second surface 42 of the divider 36, such asdepicted in FIG. 6 and discussed further below. In some embodiments, thecross-directional divider 38 extends away from the first surface 40 in adirection substantially perpendicular to a plane defined by the firstsurface 40. In some embodiments, the cross-directional divider 38 canextend away from the second surface 42 in a direction substantiallyperpendicular to a plane defined by the second surface 42.

The cross-directional divider 38 can include a cross-directionalthickness 48 and a machine-directional length 50. The cross-directionalthickness 48 of the cross-directional divider 38 is to be measured inthe cross direction 34 for the headbox 16. In some embodiments, thecross-directional thickness 48 of the cross-directional divider 38 canbe between about 0.5 mm to about 10 mm. The machine-directional length50 of the cross-directional divider 38 is to be measured in the machinedirection 32 for the headbox 16 between a proximal end 54 of thecross-directional divider 38 and a distal end 56 of thecross-directional divider 38. In some embodiments, themachine-directional length 50 of the cross-directional divider 38 canvary based on the length 46 of the divider 36. In some embodiments, suchas the embodiment depicted in FIG. 2 , the machine directional length 50of the cross-directional divider 38 can be less than the length 46 ofthe divider 36.

The height 52 of the cross-directional divider 38 is to be measured in adirection perpendicular to the machine direction 32 and the crossdirection 34 of the headbox 16 and from the surface of the divider 36from which it extends. As an example, the height 52 of thecross-directional divider 38 is measured from the first surface 40 ofthe divider 36 in a direction perpendicular to the machine direction 32and the cross direction 34 of the headbox 16, such as illustrated inFIG. 3 .

The height 52 of the cross-directional divider 38 can vary along themachine directional length 40 of the cross-directional divider 38. Forexample, in the embodiment depicted in FIG. 2 , the height 52 of thecross-directional divider 38 at the proximal end 54 of thecross-directional divider 38 is greater than the height 52 of thecross-directional divider 38 at the distal end 56 of thecross-directional divider 38. In some embodiments, the cross-directionaldivider 38 can include a first section 58 that has a substantiallyconstant height 52 and a second section 60 that has a decreasing height52 along the machine-directional length 50 of the cross-directionaldivider 38. As illustrated in the embodiment of FIG. 2 , the secondsection 60 of the cross-directional divider 38 can decrease in height 52in a linear fashion. Of course, it is contemplated that the height 52 ofthe cross-directional divider 38 may decrease between a proximal end 54and a distal end 56 of the cross-directional divider 38 in other ways.Not to be bound by theory, but it is believed that decreasing the height52 along the machine-directional length 50 of the cross-directionaldivider 38 can help with intermingling of fibers between various zonesin the headbox 16 if such a decrease in height creates a gap between thecross-directional divider 38 and the foraminous element 22, as will bediscussed in more detail below.

FIG. 4 illustrates a cross-sectional view of divider 36 within theheadbox 16, as viewed at the inlet 26 of the headbox 16. As depicted inFIG. 4 , divider 36 can have a width 44 (as labeled in FIG. 3 ) thatsubstantially spans across the width 62 of the internal volume 24 of theheadbox 16 at the inlet section 26. In some embodiments, the width 44 ofthe divider 36 can be at least 90%, or more preferably at least 95%, ofthe width 62 of the internal volume 24 of the headbox 16 at the inletsection 26. The first surface 40 and the second surface 42 of thedivider 36 can form a z-directional divider 64 for the headbox 16. Inother words, the divider 36 can form a z-directional divider 64 byforming a first z-directional layer 66 and a second z-directional layer68 within the headbox 16.

In some embodiments, the divider 36 can be positioned in the headbox 16such that the z-directional divider 64 is evenly positioned between theinternal surface 74 of the top of the headbox 16 and the internalsurface 75 of the bottom of the headbox 16. Such a configurationprovides for an equal thickness for the first z-directional layer 66 ofthe headbox 16 and the second z-directional layer 68 of the headbox 16.Of course, the divider 36 can be moved in a z-directional manner withrespect to the headbox 16 to provide different target thicknesses forthe first z-directional layer 66 of the headbox 16 and the secondz-directional layer 68 of the headbox 16, and in turn, differentthicknesses for the corresponding layers 82, 84 of a substrate asdescribed later herein.

As also depicted in FIG. 4 , the cross-directional dividers 38 cancreate zones 70 a, 70 b, 70 c within the headbox 16, or within aparticular z-directional layer in the headbox 16. In the embodimentdepicted in FIG. 4 , the two cross-directional dividers 38 can create afirst zone 70 a, a second zone 70 b, and a third zone 70 c that eachform part of the first z-directional layer 66 of the headbox 16. Forexample, the first zone 70 a and the second zone 70 b are separated fromone another by the left-most cross-directional divider 38 and the secondzone 70 b and the third zone 70 c are separated from one another by theright-most cross-directional divider 38. When creating zones that aredistinguished from one another in the headbox 16 in a cross-directionalmanner at the inlet 26 of the headbox 16, it is preferable that thecross-directional divider(s) 38 preferably have a height 52 (such aslabeled in FIG. 3 ) that substantially spans the distance between thetwo surfaces that provide a thickness for a particular layer of theheadbox 16 at least near the inlet 26 of the headbox 16 (e.g., at theproximal end 54 of the cross-directional divider 38). For example, inthe embodiment depicted in FIG. 4 , it is preferable if thecross-directional dividers 38 of the divider 36 include a height 52 (aslabeled in FIG. 3 ) that substantially spans the distance 72 between thefirst surface 40 of the divider 36 and the internal surface 74 of theheadbox 16 that defines the thickness of the first layer 66 in theheadbox 16 at the inlet 26 of the headbox 16. For example, the height 52of the cross-directional dividers 38 can be at least 90%, or morepreferably at least 95%, of the distance 72 between the first surface 40of the divider 36 and the internal surface 74 of the headbox 16 definingthe thickness of the first layer 66 of the headbox 16.

While FIG. 4 illustrates an embodiment including a divider 36 with twocross-directional dividers 38 that extend from the first surface 40, itis contemplated that other arrangements for creating cross-directionalzones within a headbox 16 can be created and utilized to create zonedsubstrates. For example, in some embodiments, a headbox 16 can includeone or more cross-directional dividers 38, without any z-directionaldivider 64, such that there is only one z-directional layer 66 withinthe headbox 16. It is also contemplated that a divider 36 could have asingle cross-directional divider 38 extending from only one surface 40or 42 to create only two zones within a particular z-directional layerwithin the headbox 16, or there could be three or more cross-directionaldividers 38 that create four or more zones within a particularz-directional layer within the headbox 16. As illustrated in FIG. 4 , insome embodiments, the divider 36 can create a z-directional layer 68that only includes a single zone 73. As will be described in otherembodiments, the divider 36 can include at least one cross-directionaldivider 38 extending from the first surface 40 and at least onecross-directional divider 38 extending from the second surface 42 thatcreate more than one zone in each of the z-directional layers 66, 68 ofthe headbox 16.

In embodiments that include a cross-directional divider 38 and az-directional divider 64, the cross-directional divider(s) 38 can beintegrally formed with the z-directional divider 64. It is alsocontemplated that the cross-directional divider 38 can be formedseparately from the z-directional divider 64, but be coupled to thez-directional divider 64, such as, for example, welds, adhesives, orother suitable bonding techniques.

The cross-directional divider(s) 38 and the z-directional divider(s) 64can be formed from any suitable material. For example, thecross-directional divider(s) 38 and the z-directional divider(s) 64 canbe formed from metals (e.g., steel, aluminum, etc.), plastics, or othersuitable substances. In a preferred embodiment, the cross-directionaldivider(s) 38 and the z-directional divider(s) 64 can be formed from orcoated with polytetrafluoroethylene (PTFE), as such dividers 38, 64 canprevent sticking of fibers, and particularly of some additives, such assuperabsorbent material, to the dividers 38, 64.

Supply of fibers and additional additives can be supplied to the variouslayers and zones of the headbox 16 to provide various configurations ofa substrate. FIG. 4 also illustrates how fibers and/or additives can beprovided to the headbox 16 to provide a zoned substrate 10, such asillustrated in FIG. 5A. For example, with the use a cross-directionaldivider 38 in headbox 16 as illustrated in FIG. 4 , a first supply 14 offibers can be transferred to the second zone 70 b of the first layer 66of the headbox 16, such as through conduit(s) 18 coupled to inlet ports76 b that supply the second zone 70 b of the first layer 66 of theheadbox 16. A second supply 15 of fibers can be transferred to the firstzone 70 a of the first layer 66 of the headbox 16, for example, such asthrough the conduit(s) 19 coupled to inlet ports 76 a in the first zone70 a of the first layer 66 of the headbox 16. As illustrated in FIG. 1 ,the conduit 19 that provides the second supply 15 of fibers could besplit to supply the first zone 70 a and the third zone 70 c, or therecould be two separate conduits 19 that are connected to the secondsupply 15 of fibers and that supply the first and third zones 70 a, 70c. In some embodiments of manufacturing a zoned substrate 10, such asthe substrate 10 in FIG. 5A, the second supply 15 of fibers can also betransferred to the third zone 70 c of the first layer 66 of the headbox16, such as through inlet ports 76 c that supply the third zone 70 c ofthe first layer 66 of the headbox. Importantly, while pairs of inletports 76 a, 76 b, 76 c are each shown as supplying the first zone 70 a,the second zone 70 b, and the third zone 70 c of the first layer 66 ofthe headbox 16, respectively, it is contemplated that there could be asingle inlet port or three or more inlet ports that supply a respectivecross-directional zone and/or layer of the headbox 16.

The first supply 14 of fibers and the second supply 15 of fibers can betransferred through the headbox 16 in the machine direction 32 for theheadbox 16 to provide the substrate 10. For example, referring back toFIG. 1 , in a foam forming manufacturing technique the first supply 14of fibers and the second supply 15 of fibers can be transferred to theheadbox 16 in a foam slurry. As the first supply 14 of fibers and thesecond supply 15 of fibers are transferred through the headbox 16, thefoam slurry incorporating the first supply 14 of fibers and the foamslurry incorporating the second supply 15 of fibers can be dewatered byvacuum elements 30 as the fibers are deposited on one or more of theforaminous elements 20, 22, as discussed above.

With the configuration noted above, the first supply 14 of fibers thatis transferred to the second zone 70 b of the headbox 16 and that istransferred through the headbox 16 can provide the substrate 10 asillustrated in FIG. 5A with a zone 80 b. The second supply 15 of fibersthat is transferred to the first zone 70 a and the third zone 70 c ofthe headbox 16 and that is transferred through the headbox 16 canprovide the substrate 10 with zones 80 a and 80 c, respectively. Thesubstrate 10 can be at least partially dewatered through the headbox 16as it exits the headbox 16 at the outlet 28 of the headbox 16. Thesubstrate 10 can be further dried, if necessary, and handled viaequipment and processes as is known in the art.

Thus, FIG. 5A provides for a zoned substrate 10 including two or morezones within a particular layer of the substrate 10. Specifically, thezoned substrate 10 includes three zones 80 a, 80 b, 80 c within a singlelayer 82 that forms zoned substrate 10. The zoned substrate 10 canprovide the advantage of having a central zone 80 b that includes fibers(with or without additives) that are different than the fibers (with orwithout additives) in zones 80 a and 80 c. As an example, the zonedsubstrate 10 could be configured to provide an absorbent material thathas absorbent fibers in the first zone 80 a, the second zone 80 b, andthe third zone 80 c, but with an additive being present in the secondzone 80 b, such as superabsorbent material, but not in the first andthird zones 80 a, 80 c. In another embodiment, the zoned substrate 10could be configured to provide a combination of an intake/distributionmaterial that has fibers in the first zone 80 a and the third zone 80 cthat function particularly well as distribution fibers (e.g., such as asoftwood pulp fiber, eucalyptus pulp fiber, or fine regeneratedcellulose fiber and a binder fiber), and can have fibers in the secondzone 80 b that function particularly well as intake/acquisition fibers(e.g., such as a crimped PET fiber with a fiber diameter greater than 3deniers and a binder fiber).

In another example, a two layer zoned substrate 110 is illustrated inFIG. 5B. The zoned substrate 110 can include a first layer 82 and asecond layer 84. Referring back to FIG. 4 , a first supply 14 of fiberscan be transferred to the second zone 70 b of the first layer 66 of theheadbox 16, such as through conduit(s) 18 coupled to inlet ports 76 bthat supply the second zone 70 b of the first layer 66 of the headbox16. A third supply 17 of fibers (as labeled in FIG. 1 ) can be suppliedto the second layer 68 of the headbox 16, such as through conduit 21coupled to inlet ports 78 a, 78 b, 78 c. As previously noted, conduit 21can be branched to feed multiple inlet ports 78 a, 78 b, 78 c, and/ormultiple conduits 21 can transfer the third supply 17 of fibers to inletports 78 a, 78 b, 78 c of the second layer 68 of the headbox 16. Indoing so, the first supply 14 of fibers can provide a first layer 82 ofthe substrate 110 in a central zone 80 b and the third supply 17 offibers can provide a second layer 84 of the substrate 110. Through theuse of the two cross-directional dividers 38 in the headbox 16, thefirst layer 82 of the substrate 110 including fibers from the firstsupply 15 of fibers can be controlled to be of a narrowercross-directional width than the second layer 84 of the substrate 110that includes fibers from the third supply 17 of fibers.

In some embodiments, the zoned substrate 110 can include a two layeredsubstrate 110 in which the first layer 82 includes fibers that aredifferent from the fibers of the second layer 84. For example, in oneexample, the zoned substrate 110 can be configured to provide anabsorbent material that includes synthetic fibers in the first layer 82in the zone 80 b that function particularly well as intake/acquisitionfibers (e.g., such as a crimped PET fiber with a fiber diameter greaterthan 3 deniers and a binder fiber) and absorbent fibers in the secondlayer 84, such as cellulosic fibers. In some embodiments, the secondlayer 84 can include fibers other than just cellulosic fibers, includingother absorbent fibers and/or non-absorbent fibers. In some embodiments,the second layer can include an additive, such as a particulate ofsuperabsorbent material.

Another embodiment of a two layer zoned substrate 210 is illustrated inFIG. 5C. The substrate 210 can include a first layer 82 and a secondlayer 84. The first layer 82 of the substrate 210 can be formed in someembodiments in a similar manner to substrate 10 as described above andas illustrated in FIG. 5A. Referring back to FIG. 4 , a first supply 14of fibers can be transferred to the second zone 70 b of the first layer66 of the headbox 16, such as through conduit(s) 18 (as labeled in FIG.1 ) coupled to inlet ports 76 b that supply the second zone 70 b of thefirst layer 66 of the headbox 16. A second supply 15 of fibers (aslabeled in FIG. 1 ) can be transferred to the first zone 70 a and thethird zone 70 c of the headbox 16 and can be transferred through theheadbox 16 to provide the first layer 82 of the substrate 210 with zones80 a and 80 c, respectively. A third supply 17 of fibers (as labeled inFIG. 1 ) can be supplied to the second layer 68 of the headbox 16, suchas through conduit 21 coupled to inlet ports 78 a, 78 b, 78 c. In suchan embodiment, the first supply 14 of fibers can provide a first layer82 of the substrate 210 with a second zone 80 b and the second supply 15of fibers can provide the first layer 82 of the substrate 210 with thefirst and second zones 80 a, 80 c, respectively, that surround thesecond zone 80 b in the first layer 82. The third supply 17 of fiberscan provide a second layer 84 of the substrate 210. Thecross-directional location of the two cross-directional dividers 38 inthe headbox 16 can control the cross-directional width of each zone 80a, 80 b, 80 c in the first layer 82 of the substrate 210.

In some embodiments, the zoned substrate 210 of FIG. 5C can include atwo layered substrate 210 in which the first layer 82 includes fibersthat are different from the fibers of the second layer 84. The zonedsubstrate 210 can provide the advantage of having a central zone 80 bthat includes fibers (with or without additives) that are different thanthe fibers (with or without additives) in zones 80 a and 80 c within thefirst layer 82 of the substrate 210. As an example, the zoned substrate210 could be configured to provide an absorbent material that has fibersin the first zone 80 a and the third zone 80 c that functionparticularly well as distribution fibers (e.g., such as a softwood pulpfiber, eucalyptus pulp fiber, or crosslinked pulp fiber and a binderfiber), and can have fibers in the second zone 80 b that functionparticularly well as intake/acquisition fibers (e.g., such as a crimpedPET fiber with a fiber diameter greater than 3 deniers and a binderfiber). The substrate 210 can also include binder material, such asbinder fibers, in one or more zones 80 a, 80 b, 80 c of the first layer82. In some embodiments, the substrate 210 can include absorbent fibersin the second layer 84 that function well as absorbent fibers, and insome preferred embodiments, can include additional fibers and/oradditives in the second layer 84. For example, the second layer 84 canbe configured to include binder fibers and/or particulates such assuperabsorbent material.

Of course, a variety of other configurations of zoned substrates can beconfigured based on the divider 36 including two cross-directionaldividers 38 and a single z-directional divider 64 as shown and describedabove based on the fiber and additive configurations to various zonesand layers of the headbox 16.

Additionally, other zoned and/or layered substrates can be made throughthe construction of different dividers for the headbox 16. As but oneadditional example, another alternative divider 136 is illustrated inFIG. 6 . The divider 136 can include a first surface 40 that includestwo cross-directional dividers 38 spaced apart from one another thatextend away from the first surface 40. The divider 136 can include asecond surface 42 that includes two cross-directional dividers 38 spacedapart from one another that extend away from the second surface 42. Asillustrated in FIG. 6 , the cross-directional dividers 38 extending awayfrom the first surface 40 can be cross-directionally aligned with thecross-directional dividers 38 extending away from the second surface 42.However, it is contemplated that the spacing of the cross-directionaldividers 38 on the first and second surface 40, 42 in thecross-direction 34 of the headbox 16 can be varied based on theresultant zoned substrate that is desired to be manufactured.Additionally, it is contemplated that the divider 136 could include onlyone cross-directional divider 38 on one or more of surfaces 40, 42and/or three or more cross-directional dividers 38 on one or more ofsurfaces 40, 42.

FIG. 7 illustrates an exemplary zoned substrate 310 that can bemanufactured by utilizing divider 136 in headbox 16 as described in theprocesses noted above with respect to FIGS. 1 and 4 . For example, thezoned substrate 310 can include a first layer 82 and a second layer 84.The first layer 82 can include zones 80 a, 80 b, and 80 c. The secondlayer 84 can include zones 86 a, 86 b, 86 c.

As discussed above with respect to other embodiments of zoned substrates10, 110, 210, one or more of the zones 80 a, 80 b, 80 c in the firstlayer 82 and one or more of the zones 86 a, 86 b, 86 c can by suppliedby various supplies of fibers (with or without additives) that canprovide various characteristics to the zoned substrate 310. As but oneexample, the first layer 82 of the zoned substrate 310 can be configuredsuch that the second zone 80 b includes fibers from a first supply 14 offibers and a first zone 80 a and third zone 80 c include fibers from asecond supply 15 of fibers. As discussed above, one preferableconstruction for such a layer 82 for a zoned substrate 310 may be tohave the fibers from the first supply 14 of fibers in the second zone 80b include fibers that provide particular benefits for intake/acquisitionfunctionality (e.g. a crimped PET fiber with a fiber diameter greaterthan 3 deniers and a binder fiber fibers). The fibers from the secondsupply 15 of fibers in the first and third zones 80 a, 80 c,respectively, of the first layer 82 can include fibers that provideparticular benefits for distribution functionality (e.g., a softwoodpulp fiber, eucalyptus pulp fiber, or crosslinked pulp fiber and abinder fiber fibers).

The second layer 84 can include first and third zones 86 a, 86 c,respectively, that include fibers from a third supply 17 of fibers thatmay include absorbent fibers. The second zone 86 b of the second layer84 of the substrate 310 can include particulates, such as from a supply23 of particulates (e.g., SAM), as labeled in FIG. 1 . The supply 23 ofparticulates can be transferred to the headbox 16 via a conduit 25. Thesupply 23 of particulates, in some embodiments, can also include fibers,such as, but not limited to, absorbent fibers. As a result, the secondlayer 84 of the substrate 310 can include first and third zones 86 a, 86c, respectively, that can include absorbent fibers and can include asecond zone 86 b that includes additional additives (such as SAM) and/orabsorbent fibers.

As can be seen from the examples of the substrates 10, 110, 210, 310 asdescribed herein, the use of one or more cross-directional dividers 38,and where desired, one or more z-directional dividers 64, can provide avery functionalized, zoned substrate 10, 110, 210, 310 with variouszones being created for enhancements of specific functionality for theend use in which the substrate 310 may be used in. In some embodiments,the zoned substrates as described herein can be utilized as part of oras an absorbent system in a personal care absorbent article. Forexample, the substrates 10, 110, 210, 310 can be utilized as part of anabsorbent system in an absorbent article. It is also contemplated thatthe substrates 10, 110, 210, 310 could be utilized as part of or anentire absorbent article itself other than a personal care absorbentarticle, such as, for example a wipe, wiper, bath or facial tissue, ortowel.

Not to be bound by theory, but it is believed that the use ofz-directional dividers 64 and/or cross-directional dividers 38 canprovide enhanced control of purity gradients at the interface betweenlayers of a substrate and at the interface between adjacent zones withina particular layer of the substrates, respectively. For example, it isbelieved that that the height 52 of the cross-directional dividers 38with respect to the dimensions of the headbox 16 can help separate zones(e.g., 70 a, 70 b, 70 c) within a layer (e.g., 66) of the headbox 16 tocontrol the fibers that are being transferred through the headbox 16 andformed into a substrate having interfaces 81 between zones (e.g., 80 a,80 b, 80 c) of a substrate 10 with a higher purity gradient. Inembodiments that have a gap between the cross-directional divider 38 andthe headbox 16, fibers from adjacent zones (e.g., 70 a, 70 b, 70 c) ofthe headbox 16 can intermingle in such a gap area as the fibers aretransferred through the headbox 16, and thus, can create zones (e.g., 80a, 80 b, 80 c) of a substrate 10 with a lower purity gradient. A similarintermingling could occur between layers (e.g., 66, 68) in the headbox16 by having a z-directional divider 64 that has a width 44 that doesnot span the full width of the headbox 16.

In addition, it is believed that the machine directional length 50 ofthe cross-directional dividers 38 may be particularly controlled toprovide a desired purity gradient between adjacent zones within thesubstrate (e.g., zones 80 a, 80 b in substrate 10 based on zones 70 a,70 b of headbox 16). For example, it is believed that by having across-directional divider 38 that is shorter in length, a lower puritygradient can be achieved between adjacent zones (e.g., 80 a, 80 b) of asubstrate as compared to a longer cross-directional divider 38. Byhaving a shorter machine directional length 50 of the cross-directionaldivider 38, more fiber intermixing can occur at the interface 81(labeled in FIG. 5A) between adjacent zones (e.g., 80 a, 80 b) of thesubstrate 10 after the cross-directional divider 38 and create a lowerpurity gradient at interface 81. A longer machine directional length 50of the cross-directional divider 38 can allow for greater formation ofthe substrate through the headbox 16 while the fibers are stillrelatively contained within separate zones, and thus, decrease theamount of fiber and/or particulate intermixing between adjacent zones(e.g., 80 a, 80 b) of a substrate while the substrate is being formedand transferring through the headbox 16, and thus, create a higherpurity gradient at interface 81.

In a similar respect, the machine directional length 46 of the divider36 (which can also be the machine directional length of thez-directional divider 64) can help control a purity gradient betweenadjacent layers within the substrate (e.g., layers 82, 84 in substrate210 based on layers 66, 68 of headbox 16). For example, a divider 36having a shorter machine directional length 46 can provide a lowerpurity gradient at an interface 81 between adjacent z-directional layers(e.g., 82, 84) of a substrate as compared to a longer machinedirectional length 46 of the divider 36. A longer machine directionallength 46 of the divider (and thus, the machine directional length ofthe z-directional divider 64) can allow for greater formation of thesubstrate through the headbox 16 while the fibers are still relativelycontained within separate layers, and thus, decrease the amount of fiberand/or particulate intermixing at the interface 81 between adjacentlayers (e.g., 82, 84) while the substrate is being formed andtransferring through the headbox 16, and thus, create a higher puritygradient at interface 81. In some embodiments, it is preferable to havea machine directional length 46 of the divider 36 that is at least 50%,or at least 55%, or at least 60%, or at least 65%, or at least 70%, orat least 75% or more of the machine directional length L of the headbox16.

It is believed that there may be advantages to having some substratesformed with lower purity gradients at the interface 81 between adjacentlayers and/or zones, whereas there may be advantages to having somesubstrates formed with higher purity gradients at the interface 81between adjacent layers and/or zones.

EXAMPLES

Experimental codes were formed utilizing a foam-forming method asdescribed above with respect to FIG. 1 along with varying the dividerconstruction. Purity gradients were measured at various interfaces 81between zones of the substrates to determine how well a divider 36including at least one cross-directional divider 38 can control themixing at an interface 81 between zones. Relative layer thicknesses werealso measured to determine the ability to control a relative thicknessof a particular layer with respect to a target relative thicknesssetting in the headbox 16.

The surfactant used in the foam slurry for each code was Stantex H 215UP, available from Pulcra Chemicals, which is an aqueous solution ofalkyl polyglucosides based on natural fatty alcohol C8-C10. The codeswere produced to attempt to make a substrate similar to the substrate210 shown in FIG. 5C that includes three cross-directional zones 80 a,80 b, 80 c in a first layer 82. The second layer 84 was desired to havea uniform construction, or in other words, only a single zone. Toprovide such a configuration, reference is made to the headbox 16configuration of FIG. 4 . The inlets 76 a of the first zone 70 a of thefirst layer 66 of the headbox 16 and inlets 76 c of the third zone 70 cof the first layer 66 of the headbox 16 were provided with exemplarydistribution layer materials of crosslinked cellulosic CMC 535 fibersand T 255 binder fibers. The inlets 76 b of the second zone 70 b of thefirst layer 66 of the headbox 16 were provided with exemplary intakelayer materials of synthetic based fibers of PET fibers and T 255 binderfibers. All of the inlets 78 a, 78 b, and 78 c of the second layer 68 ofthe headbox 16 were provided with materials to construct an absorbentlayer by providing NBSK fibers, crosslinked cellulosic CMC 535 fibers, T255 binder fibers, and superabsorbent material particulates.

Table 1 provides three exemplary codes that were formed utilizing fiberand/or particulates in the layers 66, 68 of the headbox 16 as describedabove to provide substrates 210A, 210B, and 210C. The only variablebetween codes documented in Table 1 was the type of divider 36 (or lackthereof) used with the headbox 16 to produce each substrate. For code A,a divider 36 including two cross-directional dividers 38 extending fromthe first surface 40 of the divider 36 was used, such as the divider 36illustrated in FIG. 3 to make substrate 210A. For code B, a divider 36including no cross-directional dividers 38 was used, such that thedivider 36 only provided a z-directional divider 64 to make substrate210B. For code C, no divider 36 was used in the headbox 16 to makesubstrate 210C. In each of the codes, a small percentage of coloredfiber was added to the center zone 80 b for first layer 82 to helpvisually depict the amount of mixing between adjacent zones and layersof each material code. The colored fiber used in the center zone 80 bwas an acrylic fiber with 3 mm fiber length and was provided at 3 wt %in the center zone 80 b of the first layer 82 based on total weight ofthe fibers at that zone, approximately 1.2 gsm.

TABLE 1 Material Code Information Layer 1 Layer 2 Outside zones CenterZone Absorbent body CMC T255 PET T255 T255 CMC 535 binder curly binderbinder NBSK 535 fibers fibers fibers fibers fibers fibers fibers SAM % %Code (gsm) (gsm) (gsm) (gsm) (gsm) (gsm) (gsm) (gsm) binder SAM A 31 926 14 23 30 23 400 4.8 84 B 31 9 26 14 23 30 23 400 4.8 84 C 31 9 26 1423 30 23 400 4.8 84

FIGS. 8A-8C provide photographs depicting the substrates 210A, 210B,210C formed by material Codes A, B, and C, respectively. The coloredfibers that were used in the center zone 80 b help visually demonstratethe amount of mixing occurring at an interface 81 between adjacent zones80 a and 80 b and zones 80 b and 80 c in the substrates. For example,FIG. 8A that used a divider 36 including two cross-directional dividers38 depicts the colored fibers of zone 80 b (and thus the other fibers ofthe center zone 80 b) of the substrate 210A were relatively containedbetween the interfaces 81 between itself and zone 80 a and zone 80 c.However, FIG. 8B that depicts a substrate 210B that used a divider 36without any cross-directional dividers 38 and FIG. 8C that depicts asubstrate 210C that did not use a divider 36 whatsoever shows asignificantly higher amount of dispersion of the colored fiber from thecenter zone 80 b at the interfaces 81 between zone 80 a and 80 b andbetween zone 80 b and zone 80 c. Thus, Codes B and C providingsubstrates 210B, 210C visually show a lower purity level of theinterfaces 81 between zones 80 a and 80 b, and between 80 b and 80 c inthe first layer 82.

Substrate samples from each experimental code substrates 210A, 210B,210C were harvested for analysis according to the Purity Gradient TestMethod and Layer Thickness Test Method as described in the Test Methodssection herein. The Purity Gradient Test Method provides quantifiablecharacteristics for the amount of mixing at an interface betweenadjacent zones of a layer, as documented in Table 2.

TABLE 2 Results of Purity Gradient Testing for Adjacent Zones within aLayer Code A (Substrate 210A) Code B (Substrate 210B) Code C (Substrate210C) zone zone zone zone zone zone transition transition transitiontransition transition transition width (cm) slope (gray/cm) width (cm)slope (gray/cm) width (cm) slope (gray/cm) Average 2.5 52 3.9 28 3.8 25Std. Dev. 0.3 9 0.5 1 0.5 9 Max. 2.8 63 4.4 30 4.3 40 Min. 2.1 43 3.3 273.4 16 n 5 5 5 5 5 5

The results of the Purity Gradient testing for adjacent zones within alayer of a substrate from Table 2 show that a cross-directional divider38 provides a substantial increase in control of the amount of mixingbetween adjacent zones within a layer of a substrate. For example, CodeA demonstrated a substrate 210A having two zones in a layer with aninterface having a purity gradient that includes a transition width of2.5 cm, whereas Codes B and C only provided transition widths of 3.9 cmand 3.8 cm, respectively, for substrates 210B and 210C. Thus, preferablefoam-formed substrates including adjacent zones in a layer can providean interface between zones having a transition width of less than 3.8cm, or more preferably, less than 3.0 cm., or more preferably, less than2.8 cm.

Additionally, Code A demonstrated a substrate 210A having two zones in alayer with an interface having a purity gradient that includes atransition slope of 52 gray/cm, whereas Codes B and C only provided asubstrate 210B and 210C with an interface having a purity gradient thatincludes a transition slope of 28 gray/cm and 25 gray/cm, respectively.The higher the transition slope of the purity gradient, the greater thelevel of purity exists at the interface between zones. Thus, preferablefoam-formed substrates including adjacent zones in a layer can providean interface between zones having a transition slope of greater than 28gray/cm, or more preferably greater than 30 gray/cm, or even morepreferably greater than 40 gray/cm.

By using a foam forming process with a divider 36 havingcross-directional dividers 38, a substrate can be produced with aninterface 81 between adjacent zones that provides a level of beneficialmixing to provide for proper integrity of the structure and fluiddistribution between adjacent zones, yet the mixing can be controlledsufficiently at the interface 81 to still provide sufficient puritybetween different zones such that the intended purpose of differentzones based on their fiber composition selection can be accomplished forthe substrate 210. For example, FIG. 10 shows the efficiency of Code Ain comparison to Codes B and C in terms of fluid distribution perproduct length. As shown in FIG. 10 , Code A demonstrated a more evendistribution of fluid for the entire substrate. Specifically, themoisture was lower near the insult as it was more evenly distributedthroughout the length of the substrate. Code A demonstrated a highermoisture level than Code B or Code C at approximately 16-17 cm of lengthof the substrate. By having more efficient fluid distribution throughoutthe length of a substrate, substrates can be created that have loweramounts of material to perform the same functionality, and thus, provideraw material and cost savings for a particular intended end use. If usedin personal care absorbent articles, the enhanced fluid distributionefficiency can also lead to thinner products, which may be moreflexible, discrete, and/or comfortable for an end user.

Additionally, higher purity gradients between zones and/or layers canprovide enhanced fluid intake rates due to distinctive intake anddistribution zones in the first layer and an absorbent layer in thesecond layer. By having a higher purity gradient between zones and/orlayers, absorbent substrates used in absorbent articles can performmultiple liquid handling functions, such as intake, distribution, andstorage, such as for use in diapers or wiping, which can include fluidpick-up and lock-up, in multiple different structures that are designedfor such particular functions. Notably, this is completed without theuse of adhesives at such interfaces, as with other substrates in theprior art that look to make absorbent composites from separate materialsthat are adhered together. Adhesives at such interfaces can lead tolower performance of distribution and intake as the adhesives can act asa barrier to fluid handling.

Layer relative thicknesses and purity of layers can also be controlledmore readily through the use of dividers 36 that provide a z-directionaldivider 64. For the testing herein involving substrates 210A, 210B, 210Cincluding superabsorbent material, the Layer Relative Thickness TestMethod was utilized that employed microCT equipment. The Layer RelativeThickness Test Method is described in detail in the Test Methods sectionherein. Cross-sectional images of material Codes A-C providingsubstrates 210A-210C described above were taken utilizing microCTimaging equipment and are depicted in FIGS. 9A-9C, respectively. Table 3provides the results of the relative layer thickness for a substrate 210including a second layer 84 that includes superabsorbent materialparticles, where the relative thickness of the layer is measured as apercentage of the overall thickness of the substrate.

TABLE 3 Second Layer Relative Thickness Results Code A Code B Code C(Substrate 210A) (Substrate 210B) (Substrate 210C) Second Layer SecondLayer Second Layer Relative Relative Relative Thickness ThicknessThickness Average 34% 53% 70% Std. Dev.  6%  8%  8% n 7 7 7

The relative layer thickness results documented in Table 3 demonstratethat the use of a divider 36 providing a z-directional divider 64 in theheadbox 16 provides substantially more control over the purity of thelayers 82, 84, and thus, more control over the layer relative thicknessof a substrate 210, particularly where a layer includes particulatematerial (e.g., superabsorbent material particles). In producing Codes Aand B (substrates 210A and 210B), the divider 36 was set up in theheadbox 16 such that the divider 36 was evenly spaced in thez-directional 35 thickness of the headbox 16 (as illustrated in FIG. 4 )to try to produce a second layer 84 of the substrate that had the samez-directional 35 thickness as the first layer 82. In other words, thedivider 36 was positioned in the headbox 16 such that the z-directionaldivider 64 was evenly positioned between the internal surface 74 of thetop of the headbox 16 and the internal surface 75 of the bottom of theheadbox 16. The z-directional divider 64 was also configured to extendapproximately 66% into the length of the headbox 16. On the other hand,Code C (substrate 210C) did not include any divider 36 in the headbox16. With such a configuration of the divider 36 in the headbox 16 forproducing Codes A and B, the divider 36 including a z-directionaldivider 64 provided for significantly more control of the superabsorbentmaterial particles in the substrate for Codes A and B (substrates 210Aand 210B) in comparison to Code C (substrate 210C), and thus, morecontrol over the relative thickness of the second layer 84 includingsuch particulates.

Specifically, as documented in Table 3, Code A and Code B providingsubstrates 210A and 210B utilizing a divider 36 to separate first layer82 from second layer 84 provided a second layer 84 relative thickness of34% and 53% of the total thickness of the substrate 210A, 210B,respectively, whereas Code C providing substrate 210C that wasmanufactured without utilizing a divider 36 provided a relativethickness of the second layer 84 that was 70% of the total thickness ofthe substrate 210C. Because the headbox 16 and divider 36 within theheadbox 16 were configured to provide a target thickness in which thefirst layer 82 and a second layer 84 had equal thickness, Codes A and Bdisplayed the ability to control the thickness of the second layer 84including particulates (such as SAM particulates) to a closer degree tothe target thickness. In fact, Code C producing substrate 210C did notappear to provide a two layer structure at all, as the superabsorbentparticles and the fibers intended to be provided in a second layer werefound to distribute largely over a significant portion of the substrate210C, including particularly near an upper surface 92 of the substrate210C. FIG. 9C also depicts that fibers intended for the intake anddistribution zones of the upper layer migrated towards the bottomsurface 94 of the substrate 210C. Substrate 210C thus would not performas well from an intake or distribution functionality without the properfiber control. Therefore, use of a divider 36 including a z-directionaldivider 64 provides enhanced z-directional control of substrates 210Aand 210B by providing higher levels of control of the relative thicknessof the second layer 84, but also helps to provide a two layer 82, 84structure to the substrate 210A, 210B whatsoever. This control over thefibers and/or particulates is surprising from the standpoint that thefoam continues to be mobile and prone to mixing until it exits theheadbox 16 and is completely dewatered.

The configuration of the divider 36 extending at least 50% of the lengthL of the headbox 16, or more preferably at least 60% of the length L ofthe headbox 16, was believed to provide enhanced control of the mixingof the first layer 82 and the second layer 84 of the substrate 210 atthe interface 81 between layers 82, 84. Preferrable substrates caninclude a second layer 84 that includes particulates (e.g., SAMparticles) that has a relative thickness with less than 20% variancefrom the target relative thickness, or more preferably, a relativethickness that is less than 15% variance from the target relativethickness, or even more preferably, less than 10% variance from thetarget relative thickness. In some embodiments, preferable substratescan include a second layer 84 of a substrate 210A, 210B that can haveparticulates (e.g., SAM particles) and have a relative thickness lessthan 70% of the overall thickness of the structure, or more preferably,less than 60%, or in some embodiments, less than 55% of the absorbentstructure. Thus, it can be seen that by providing a divider 36 creatinga z-directional divider 64, a layer 84 can be produced to a relativethickness closer to a desired relative thickness, and therefore, canimprove the overall purity of that layer 84 with respect to theresultant substrate.

Test Methods Purity Gradient Test Method

The Purity Gradient Test Method can be used to measure the puritygradient of an interface 81 between two adjacent zones in a substrate,where the zones are in an external layer of the substrate. A digitalcamera, (such as a Sony DXC-5500), is used to take five digital imagesof each sample from a top-down view for purity gradient testing. Thesample should be placed such that the layer including the zones andinterface 81 being analyzed is facing up. The camera is set to black andwhite mode. The images are to be taken in an internal room with itslighting on. An additional light source is to be mounted on each side ofthe sample to be photographed. A Polaroid MP-4 Land Camera 44-02 stand(has ability to locate two lights on each side of sample) or similar setup is to be used to provide direct lighting on the surface of thesample. Care should be taken to ensure that no shadows are projected onthe sample when taking the images with the digital camera.

The camera should capture images that encompass the interface 81 betweenadjacent zones for which the purity gradient is desired to evaluate, aswell as at least a portion of each of such adjacent zone. For example,for samples described herein, the width of each image was approximately14 centimeters (5.5 inches). A ruler is placed near the bottom of eachimage in order to set the length scale in later analysis. The fiveimages taken for each sample should be taken at different machinedirectional locations along the interface 81. The camera is focused onthe sample using the automatic focus of the digital camera. In black andwhite mode, the images have the ability to discern the differencebetween different fiber types via color differences in the fibers in thesoftware analytical tool.

ImageJ software should be downloaded (such as from the NationalInstitute of Health (NIH)—https://imagej.nih.gov/ij/) on to a computer.The five images for each sample are loaded into the ImageJ software.Once an image is opened in ImageJ, Auto BC is set on the image tonormalize the images and the grayscale for the light fibers in one zoneshould be set to be the same as the light fibers in the other images,and likewise for the dark fibers (or particulates) of a different zonewith dark fibers (or particulates) of that zone in the other images. Theentire image is selected for analysis using the selection tool in theImageJ software. Thus, the analyzed area and width is the same for eachof the five images for each sample. The Plot Profile function in ImageJsoftware was used to obtain the gray scale as a function of distanceacross the image width. The Plot Profile function averages the grayscale for the selected area across the width of the image, and theaverage gray scale is plotted as a function of distance across theimage.

FIG. 11 illustrates ImageJ software Plot Profile function for twoexemplary codes. As illustrated in FIG. 11 , the transition width TW foreach image is measured as the length of the interface determined fromthe gray scale plot based on where the gray scale began to increase fromwhite and ending where it plateaued in the dark region. To account forthe noise in the plot, the interface is taken to begin where theincrease begins and continues to a grayscale of >30% over the startingor baseline level. For the zone surface image, a ruler was placed ineach image in order to set the length scale as noted above. For purposesherein, the purity gradient transition width value for a sampleinterface 81 is the average transition width of the five images for eachsample.

The transition slope is measured as the (change ingrayscale)/(transition width), or the slope of a line connecting datapoints at the left and right sides of the transition zone as depicted inFIG. 11 . The change in gray scale was the same for each image after theAutoBC normalization. For purposes herein, the purity gradienttransition slope value for a sample interface 81 is the averagetransition slope of the five images for each sample.

Layer Relative Thickness Test Method

The Layer Relative Thickness Test Method is used to determine aparticular layer thickness of a z-directional layer of a sampleincluding two or more z-directional layers. For each sample substrate,seven cross-sectional images are taken. Each cross-sectional sample isimaged with conventional microCT equipment, such as Bruker Skyscan 1272,to provide an image such as those illustrated in FIGS. 9A-9C. The widthof each sample for cross-sectional imaging is about 7 mm.

ImageJ software should be downloaded (such as from the NationalInstitute of Health (NIH)—https://imagej.nih.gov/ij/) on to a computer.The seven images for each sample are loaded into the ImageJ software,converted to grayscale, and rotated ninety degrees, such that theinterface 81 between separate layers 82, 84 is oriented in a generallyvertical fashion. The image is made grayscale using the Make Binaryfunction in ImageJ. Auto BC is set on the image to normalize the imagesand the grayscale for the light fibers in one layer should be set to bethe same as the light fibers in the other images, and likewise for thedark fibers (or particles) of a different layer with dark fibers (orparticles) of that layer in the other images.

As illustrated in FIG. 12 , the layer thickness LT is measured bymeasuring the width of the layer where SAM particles are present usingthe grayscale plot from the plot profile function and setting anappropriate threshold to distinguish the region such as the mid-point ofgrayscale between the pure fiber region and the pure SAM region. Thetotal thickness for a sample is the width of the area selected for theplot profile function. For purposes herein, a layer relative thicknessfor an image of a substrate is the measured layer thickness divided bythe total thickness for that image. For purposes herein, a layerrelative thickness percentage of the total thickness of a substrate iscalculated by averaging the layer relative thickness for the sevenimages.

Embodiments

Embodiment 1: A method for manufacturing a substrate, the methodcomprising: providing a first supply of fibers; providing a secondsupply of fibers; providing a headbox, the headbox comprising: a machinedirection; a cross-direction; and a first cross-directional divider thatseparates a first zone of the headbox from a second zone of the headboxin a cross-directional manner; transferring the first supply of fibersand the second supply of fibers to the headbox; and transferring thefirst supply of fibers and the second supply of fibers through theheadbox to provide the substrate.

Embodiment 2: The method of embodiment 1, wherein the first supply offibers is transferred to the first zone of the headbox and the secondsupply of fibers is transferred to the second zone of the headbox; andwherein transferring the first supply of fibers and the second supply offibers through the headbox provides the substrate with a first zonecomprising fibers from the first supply of fibers and a second zonecomprising fibers from the second supply of fibers.

Embodiment 3: The method of embodiment 1 or 2, wherein the headboxfurther comprises a z-directional divider comprising a first surface anda second surface, the second surface being opposite from the firstsurface, the z-directional divider providing a first z-directional layerin the headbox and a second z-directional layer in the headbox.

Embodiment 4: The method of any one of the preceding embodiments,further comprising a second cross-directional divider that separates thesecond zone of the headbox from a third zone of the headbox.

Embodiment 5: The method of embodiment 3, further comprising a secondcross-directional divider that separates the second zone of the headboxfrom a third zone of the headbox; wherein the first zone, the secondzone, and the third zone each form part of the first z-directional layerof the headbox.

Embodiment 6: The method of embodiment 5, wherein the first supply offibers are transferred to the second zone of the headbox in the firstz-directional layer of the headbox and the second supply of fibers aretransferred to the second z-directional layer of the headbox; andwherein transferring the first supply of fibers and the second supply offibers through the headbox provides the substrate with a first layercomprising fibers from the first supply of fibers and a second layercomprising fibers from the second supply of fibers.

Embodiment 7: The method of embodiment 6, wherein the first supply offibers comprise synthetic fibers and the second supply of fiberscomprise absorbent fibers.

Embodiment 8: The method of embodiment 5, further comprising: providinga third supply of fibers; transferring the third supply of fibers to theheadbox; and transferring the third supply of fibers through the headboxto provide the substrate.

Embodiment 9: The method of embodiment 8, wherein the first supply offibers are transferred to the first zone and the third zone of the firstz-directional layer of the headbox, the second supply of fibers aretransferred to the second zone of the first z-directional layer of theheadbox, and the third supply of fibers are transferred to the secondz-directional layer of the headbox.

Embodiment 10: The method of embodiment 9, wherein the first supply offibers comprise at least one type of distribution fiber; the secondsupply of fibers comprise at least one type of intake fiber; and thethird supply of fibers comprise absorbent fibers.

Embodiment 11: The method of any one of the preceding embodiments,further comprising: providing a supply of particulates to the headbox;and transferring the supply of particulates through the headbox toprovide the substrate.

Embodiment 12: The method of embodiment 11, wherein the particulatescomprise superabsorbent material.

Embodiment 13: The method of any one of the preceding embodiments 1,wherein the first supply of fibers are provided in a first foam slurryand the second supply of fibers are provided in a second foam slurry.

Embodiment 14: A divider for a headbox including a cross direction and amachine direction, the divider comprising: a first surface; a secondsurface, the second surface being opposite from the first surface; awidth defined in the cross direction; a length defined in the machinedirection; and a first cross-directional divider extending away from thefirst surface, the first cross-directional divider comprising across-directional thickness and a machine-directional length.

Embodiment 15: The divider of embodiment 14, wherein the firstcross-directional divider extends away from the first surface in adirectional substantially perpendicular to a plane defined by the firstsurface of the divider.

Embodiment 16: The divider of embodiment 14 or 15, wherein the firstcross-directional divider further comprises a proximal end and a distalend, and wherein a height of the first cross-directional divider asmeasured at the proximal end of the first cross-directional divider isgreater than a height of the first cross-directional divider as measuredat the distal end of the first cross-directional divider.

Embodiment 17: The divider of any one of embodiments 14-16, furthercomprising a second cross-directional divider.

Embodiment 18: The divider of embodiment 17, wherein the secondcross-directional divider extends away from the first surface of thedivider and is spaced apart from the first cross-directional divider inthe cross direction.

Embodiment 19: The divider of claim 17, wherein the secondcross-directional divider extends away from the second surface of thedivider.

Embodiment 20: A headbox for manufacturing a substrate, the headboxincluding a machine direction and a cross direction, the headboxcomprising: an inlet; an outlet; an internal chamber; and a divider atleast partially within the internal chamber, the divider comprising: afirst surface; a second surface, the second surface being opposite fromthe first surface; a width defined in the cross direction; a lengthdefined in the machine direction; and a first cross-directional dividerextending away from the first surface of the divider, the firstcross-directional divider comprising a cross-directional thickness and amachine-directional length; wherein the divider separates a firstz-directional layer of the headbox from a second z-directional layer ofthe headbox; and wherein the first cross-directional divider separates afirst zone of the headbox from a second zone of the headbox in across-directional manner, the first zone and the second zone being inthe first z-directional layer.

Embodiment 21: The headbox of embodiment 20, wherein the divider furthercomprises a second cross-directional divider.

Embodiment 22: A method for manufacturing a substrate including a firstlayer and a second layer, the method comprising: providing a firstsupply of fibers; providing a supply of particulates; providing aheadbox, the headbox comprising: a machine direction; a cross-direction;a z-direction, the z-direction being perpendicular to a plane defined bythe machine direction and the cross-direction; and a divider comprisinga first surface, a second surface opposite the first surface, a widthextending in the cross-direction, and a length extending in the machinedirection, the divider separating a first z-directional layer of theheadbox from a second z-directional layer of the headbox; setting az-directional position of the divider in the headbox to provide a targetrelative thickness setting of the second z-directional layer of theheadbox; transferring the first supply of fibers and the supply ofparticulates to the headbox such that the first supply of fibers enterthe first z-directional layer of the headbox and the supply ofparticulates enter the second z-directional layer of the headbox; andcontrolling the first supply of fibers and the supply of particulatesthrough the headbox to a forming surface such that a relative thicknessof the second layer of the substrate is provided with less than 20%variation of the target relative thickness setting of the secondz-directional layer of the headbox.

Embodiment 23: The method of embodiment 22, wherein the controlling ofthe first supply of fibers and the supply of particulates through theheadbox comprises providing a divider including a length in the machinedirection of greater than 50% of a length of the headbox.

Embodiment 24: The method of embodiment 22 or 23, wherein a relativethickness of a second layer of the substrate is provided with less than10% variation of the target relative thickness setting of the secondz-directional layer of the headbox.

Embodiment 25: The method of any one of embodiments 22-24, wherein thetarget relative thickness setting of the second z-directional layer ofthe headbox is 50% of a total thickness of the headbox.

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments have been illustrated and described, itwould be obvious to those skilled in the art that various other changesand modifications can be made without departing from the spirit andscope of the invention. It is therefore intended to cover in theappended claims all such changes and modifications that are within thescope of this invention.

1. A method for manufacturing a substrate, the method comprising:providing a first supply of fibers; providing a second supply of fibers;providing a headbox, the headbox comprising: a machine direction; across direction; an inlet; an outlet; a first z-directional layer havinga height; and a first cross-directional divider that separates a firstzone of the headbox from a second zone of the headbox in across-directional manner in the first z-directional layer, the firstcross-directional divider including a height that is at least 90% of theheight of the first z-directional layer; transferring the first supplyof fibers to the first zone of the headbox at the inlet and transferringthe second supply of fibers to the second zone of the headbox at theinlet; and transferring the first supply offbers and the second supplyof fibers through the headbox to the outlet to provide the substrate. 2.The method of claim 1, wherein the first supply of fibers is transferredto the first zone of the headbox and the second supply of fibers istransferred to the second zone of the headbox; and wherein transferringthe first supply of fibers and the second supply of fibers through theheadbox provides the substrate with a first zone comprising fibers fromthe first supply of fibers and a second zone comprising fibers from thesecond supply of fibers.
 3. The method of claim 1, wherein the headboxfurther comprises a z-directional divider comprising a first surface anda second surface, the second surface being opposite from the firstsurface, the z-directional divider providing the first z-directionallayer in the headbox and a second z-directional layer in the headbox. 4.The method of claim 1, further comprising a second cross-directionaldivider that separates the second zone of the headbox from a third zoneof the headbox in a cross-directional manner in the first z-directionallayer.
 5. The method of claim 3, further comprising a secondcross-directional divider that separates the second zone of the headboxfrom a third zone of the headbox in a cross-directional manner in thefirst z-directional layer; wherein the first zone, the second zone, andthe third zone each form part of the first z-directional layer of theheadbox.
 6. The method of claim 5, wherein the first supply of fibersare transferred to the second zone of the headbox in the firstz-directional layer of the headbox and the second supply of fibers aretransferred to the second z-directional layer of the headbox; andwherein transferring the first supply of fibers and the second supply offibers through the headbox provides the substrate with a first layercomprising fibers from the first supply of fibers and a second layercomprising fibers from the second supply of fibers.
 7. The method ofclaim 6, wherein the first supply of fibers comprise synthetic fibersand the second supply of fibers comprise absorbent fibers.
 8. The methodof claim 5, further comprising: providing a third supply of fibers;transferring the third supply of fibers to the headbox at the inlet; andtransferring the third supply of fibers through the headbox to theoutlet to provide the substrate.
 9. The method of claim 8, wherein thefirst supply of fibers are transferred to the first zone and the thirdzone of the first z-directional layer of the headbox, the second supplyof fibers are transferred to the second zone of the first z-directionallayer of the headbox, and the third supply of fibers are transferred tothe second z-directional layer of the headbox.
 10. The method of claim9, wherein the first supply of fibers comprise at least one type ofdistribution fiber; the second supply of fibers comprise at least onetype of intake fiber; and the third supply of fibers comprise absorbentfibers.
 11. The method of claim 1, further comprising: providing asupply of particulates to the headbox; transferring the supply ofparticulate to the headbox at the inlet; and transferring the supply ofparticulates through the headbox to provide the substrate.
 12. Themethod of claim 11, wherein the particulates comprise superabsorbentmaterial.
 13. The method of claim 1, wherein the first supply of fibersare provided in a first foam slurry and the second supply of fibers areprovided in a second foam slurry.
 14. A divider for a headbox includinga cross direction and a machine direction and a width in the crossdirection, the divider comprising: a first surface; a second surface,the second surface being opposite from the first surface; a widthdefined in the cross direction that is at least 90% of the width of theheadbox; a length defined in the machine direction; and a firstcross-directional divider extending away from the first surface, thefirst cross-directional divider comprising a cross-directional thicknessand a machine-directional length.
 15. The divider of claim 14, whereinthe first cross-directional divider extends away from the first surfacein a directional substantially perpendicular to a plane defined by thefirst surface of the divider.
 16. The divider of claim 15, wherein thefirst cross-directional divider further comprises a proximal end and adistal end, and wherein a height of the first cross-directional divideras measured at the proximal end of the first cross-directional divideris greater than a height of the first cross-directional divider asmeasured at the distal end of the first cross-directional divider. 17.The divider of claim 14, further comprising a second cross-directionaldivider.
 18. The divider of claim 17, wherein the secondcross-directional divider extends away from the first surface of thedivider and is spaced apart from the first cross-directional divider inthe cross direction.
 19. The divider of claim 17, wherein the secondcross-directional divider extends away from the second surface of thedivider.
 20. A headbox for manufacturing a substrate, the headboxincluding a machine direction and a cross direction, the headboxcomprising: an inlet; an outlet; an internal chamber; and a divider atleast partially within the internal chamber, the divider comprising: afirst surface; a second surface, the second surface being opposite fromthe first surface; a width defined in the cross direction that is atleast 90% of a width of the internal chamber of the headbox; a lengthdefined in the machine direction; and a first cross-directional dividerextending away from the first surface of the divider, the firstcross-directional divider comprising a cross-directional thickness and amachine-directional length; wherein the divider separates a firstz-directional layer of the headbox from a second z-directional layer ofthe headbox; and wherein the first cross-directional divider separates afirst zone of the headbox from a second zone of the headbox in across-directional manner, the first zone and the second zone being inthe first z-directional layer.
 21. The headbox of claim 20, wherein thedivider further comprises a second cross-directional divider.
 22. Amethod for manufacturing a substrate including a first layer and asecond layer, the method comprising: providing a first supply of fibers;providing a supply of particulates; providing a headbox, the headboxcomprising: a machine direction; a cross-direction; a z-direction, thez-direction being perpendicular to a plane defined by the machinedirection and the cross-direction; and a divider comprising a firstsurface, a second surface opposite the first surface, a width extendingin the cross-direction, and a length extending in the machine direction,the divider separating a first z-directional layer of the headbox from asecond z-direction al layer of the headbox; setting a z-directionalposition of the divider in the headbox to provide a target relativethickness setting of the second z-directional layer of the headbox;transferring the first supply of fibers and the supply of particulatesto the headbox such that the first supply of fibers enter the firstz-directional layer of the headbox and the supply of particulates enterthe second z-directional layer of the headbox; and controlling the firstsupply of fibers and the supply of particulates through the headbox to aforming surface such that a relative thickness of the second layer ofthe substrate is provided with less than 20% variation of the targetrelative thickness setting of the second z-directional layer of theheadbox.
 23. The method of claim 22, wherein the controlling of thefirst supply of fibers and the supply of particulates through theheadbox comprises providing a divider including a length in the machinedirection of greater than 50% of a length of the headbox.
 24. The methodof claim 22, wherein a relative thickness of a second layer of thesubstrate is provided with less than 10% variation of the targetrelative thickness setting of the second z-directional layer of theheadbox.
 25. The method of claim 22, wherein the target relativethickness setting of the second z-directional layer of the headbox is50% of a total thickness of the headbox.